Issues $\rightarrow$ Volume 27, Issue 4 (2026)

Evolution of Approaches to the Formation and Functionalization of Porous Cast Aluminium: from Defectoscopy to Programmable Metamaterials

KOVALENKO V.V.$^{1}$, BYBA Ye.G.$^{1,3,5}$, MINITSKYI A.V.$^{1,3,6}$, YAMSHYNSKYI M.M.$^{1}$, SIVOLAPOV P.V.$^{1}$, CHVERTKO Ye.P.$^{1}$, LEONOV D.S.$^{2}$, and BARABASH М.Yu.$^{1–4}$

$^1$National Technical University of Ukraine ‘Igor Sikorsky Kyiv Polytechnic Institute‘, 37 Beresteiskyi Ave., UA-03056 Kyiv, Ukraine
$^2$Technical Centre of the N.A.S. of Ukraine, 13 Pokrovska Str., UA-04070 Kyiv, Ukraine
$^3$Institute of Applied Control Systems of the N.A.S. of Ukraine, 42 Academician Glushkov Ave., UA-03187 Kyiv, Ukraine
$^4$The Gas Institute of the N.A.S. of Ukraine, 39 Dekhtiarivska Str., UA-03113 Kyiv, Ukraine
$^5$E.O. Paton Electric Welding Institute of the N.A.S. of Ukraine, 11, Kazymyr Malevich Str., UA-03150 Kyiv, Ukraine
$^6$Institute of Physics and Technology of Metals and Alloys of the N.A.S. of Ukraine, 34 Academician Vernadsky Blvd., UA-03142 Kyiv, Ukraine

Received / final version: 10.07.2026 / 27.09.2026 Download PDF logo PDF

Abstract
The modern development of the aerospace, automotive, defence and mechanical-engineering sectors drives a fundamental transition from traditional monolithic metallic alloys to hybrid materials with a controlled internal architecture. Porous cast aluminium fabricated via the vacuum infiltration of a melt into a removable salt space holder represents an advanced metamaterial, whose structural and functional properties can be precisely programmed during the casting stage. This review paper provides a comprehensive analysis of the thermodynamic, hydrodynamic, and micromechanical regularities governing the formation of an open-cell porous structure. The fundamental bifilm theory is considered, explaining the defectometric advantages of the quiescent-infiltration method over traditional stochastic gas-foaming processes. The micromechanics of interpore connectivity window formation are detailed based on the physical ‘air collar’ model, alongside the mechanisms of evaporation–condensation during the sintering of sodium chloride and the unique phenomenon of thermal exfoliation. The structural and functional properties of various metallic matrices (based on Al–Si, Al–Cu, Al–Zn, and magnesium alloys’ systems) are substantiated. Furthermore, the strategic prospects of utilising porous aluminium in high-performance thermal-management systems, broadband acoustic damping, electromagnetic shielding, environmental filtration, and advanced ballistic protection are analysed.

Keywords: porous aluminium, vacuum infiltration, bifilm theory, sodium chloride, capillary pressure, hydrodynamics, metamaterials.

DOI: https://doi.org/10.15407/ufm.27.04.***

Citation: V.V. Kovalenko, Ye.G. Byba, A.V. Minitskyi, M.M. Yamshynskyi, P.V. Sivolapov, Ye.P. Chvertko, D.S. Leonov, and М.Yu. Barabash, Evolution of Approaches to the Formation and Functionalization of Porous Cast Aluminium: from Defectoscopy to Programmable Metamaterials, Progress in Physics of Metals, 27, No. 4: ***–*** (2026)

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